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This guide covers each stage of the FRI process: what to do, in what order, and what to record, so your team produces a clear, defensible result every time.
What is a Final Random Inspection?
A Final Random Inspection (FRI) is a structured quality check performed on randomly selected units from a finished production lot. The goal is to verify that what is in those cartons matches the buyer's specifications (workmanship, labeling, packaging, functional performance, and carton markings) before shipment is approved.
Select units using the agreed random sampling method so factory staff cannot hand-pick the best pieces. The sampling plan defines how many units to inspect and the decision thresholds; the selection method defines how to choose them.
When to run the FRI
Run the FRI when production is complete and the lot meets the buyer-agreed packing threshold. Some programmes allow inspection when at least 80% is packed; others require all units to be packed. Record the actual status and follow the contract.
If production is still running, use an in-process inspection under its own plan. Do not treat 80% production completion as a universal FRI rule.
Step 1: Set the AQL threshold before the inspection starts
Agree the sampling plan, inspection level, defect definitions, and acceptance numbers before inspecting. AQL is an index for a sampling plan, not the permitted percentage of bad units in the shipment.
- Critical defects: use the agreed zero-acceptance rule; this is not proof of zero defects in the lot
- Major defects: AQL 2.5, workmanship or functional issues the buyer will reject
- Minor defects: AQL 4.0, cosmetic issues that do not affect function
Major AQL 2.5 and minor AQL 4.0 are examples, not universal requirements. Use the buyer-approved values and the applicable standard.
Step 2: Calculate the required sample size
Find the initial sample-size code from lot size and the agreed inspection level. General Level II is common, but it is not mandatory for every order. The final sample size also depends on the AQL and table instructions.
For example, a lot of 3,201–10,000 units at General Level II maps to code L, with an initial sample size of 200. Follow the table instructions for the selected AQL before confirming the actual number to inspect.
- Lot size 2–8 units → sample 2
- Lot size 151–280 units → sample 32
- Lot size 1,201–3,200 units → sample 125
- Lot size 3,201–10,000 units → sample 200
- Lot size 10,001–35,000 units → sample 315
These examples refer to the initial normal, single-sampling General Level II lookup. Follow table arrows and the applicable standard for the actual AQL and plan. The calculator supports a lookup; it does not replace the complete standard.
Step 3: Select units at random
Random selection means the inspector pulls units from different positions in the lot (top cartons, bottom cartons, middle of the stack) without anyone on the factory side guiding the selection.
For palletized goods, use the agreed random method across the defined lot rather than a fixed number of convenient pallet positions. Numbered cartons can be selected with a random number generator. Record the positions and any access restriction.
Step 4: Inspect each unit against the specification
Each selected unit gets checked against the agreed spec sheet and the approved production sample. The inspector works from a structured checklist, not a blank notebook.
- Workmanship: seams, stitching, surface finish, assembly quality, hardware attachment
- Functional tests: zippers, closures, hinges, electrical function, whatever the product requires
- Appearance: color accuracy, print registration, logo placement, label content and language
- Packaging: inner box, barcode scan, carton labeling, quantity per carton
- Measurements: key dimensions checked against the specification sheet
Any deviation from spec gets logged immediately, not at the end of the walk.
Step 5: Record every defect with a photo
Every defect found gets logged at the moment of finding. The inspector records the unit identifier, the defect description, and the severity classification (critical, major, or minor).
Photograph visible findings with enough context to identify the unit and location. For dimensional or functional failures, also record the measurement or test conditions and result. A photo alone does not establish a failed requirement, and some failures cannot be shown in a still image.
Do not wait until the end of the inspection to document. Memory fades. Photo quality degrades. Log it as you find it.
Step 6: Compare totals against the AQL limits and issue the decision
After inspecting the full sample, count nonconforming units or nonconformities by severity according to the agreed plan. Record all findings, but do not count a unit twice within a class under a nonconforming-unit plan.
For example, a plan with a sample of 200 and major AQL 2.5 can specify Ac 10 and Re 11. Under a nonconforming-unit plan, 10 major nonconforming units meet this criterion and 11 reach rejection. This does not override other required checks or hold rules.
The decision is one of three outcomes:
- Pass: the sample meets the agreed criteria. Shipment still requires all release conditions and the authorized approval.
- Hold: a result, missing test or other issue needs a decision. State the owner, required action and conditions for release.
- Fail: a required criterion is not met. Hold the lot and follow the approved disposition and reinspection procedure.
State the inspection result and release authorization separately. Do not repeat sampling until a favorable result appears. Link any reinspection to the original failed report.
Step 7: Share the report before the goods move
The complete inspection report (defect log, photos, measurement results, sample size, and the pass/fail decision) must reach the factory team and the buyer before the shipment is released.
Sending the report after the goods have already shipped turns it into a formality. The report's value is in the decision it supports. If it does not arrive in time to stop a bad shipment, it has not done its job.
How to make FRIs consistent across your team
The biggest risk in a manual FRI process is variation between inspectors. One inspector logs every minor defect. Another ignores cosmetic issues. The result is that the same lot produces different outcomes depending on who ran the walk.
Lock consistency in through three practices:
- Use the same digital checklist for every FRI, not a blank form each inspector fills in their own way
- Record the same required evidence for each finding: photos for visible defects and measured or tested results where needed
- Record the AQL threshold and sample size on every report, so the basis for the decision is always documented
When every inspector follows the same process and records the same evidence, the FRI result means the same thing regardless of who ran it.
Key takeaways
- Set the AQL threshold in writing before the inspection begins, never after reviewing the sample.
- Pull units from random positions in the lot: top, bottom, and middle of the stack.
- Record findings as they occur, using photos and measured or tested results as appropriate.
- Apply the agreed counting rule and limits; record release approval separately.
- Share the complete report with the factory and the buyer before the goods ship.
Sources and related guides
Put this into practice with KaizenQ
KaizenQ gives your team a structured digital inspection workflow: defects logged with photos on the floor, a live report ready to share as soon as inspection is complete. No manual compilation. No end-of-day rework.